Center Differential: Disassembly

WARNING: This page is about a different car, the 2004 Lexus LX 470. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE
1. Using a feeler gauge, measure the high speed output gear thrust clearance.
  1. Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in.)
  2. Maximum clearance: 0.25 mm (0.0098 in.)
  Fig 1: Measuring High Speed Output Gear Thrust Clearance Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the high speed output gear radial clearance.
  1. Standard clearance: 0.035 - 0.091 mm (0.00138 - 0.00358 in.)
  2. Maximum clearance: 0.091 mm (0.00358 in.)
  Fig 2: Measuring High Speed Output Gear Radial Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE GEAR PIECE
1. Using a snap ring expander, remove the snap ring.
2. Using SST and a press, remove the front drive gear piece.
  1. SST 09950-00020, 09950-60010 (09951-00320)
  NOTE: Be careful not to drop the center differential assembly.
  
  Fig 3: Removing Front Drive Gear Piece Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT TAPER ROLLER BEARING
Using SST and a press, remove the front taper roller bearing.
1. SST 09950-00020
NOTE: Set the claw of SST to the bearing inner race securely.

Fig 4: Removing Front Taper Roller Bearing Using SST & Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HIGH SPEED OUTPUT GEAR

Fig 5: Removing High Speed Output Gear

REMOVE 2 NEEDLE ROLLER BEARINGS
REMOVE HIGH AND LOW CLUTCH SLEEVE

Fig 6: Removing High & Low Clutch Sleeve
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REMOVE HIGH SPEED OUTPUT GEAR BUSHING AND CLUTCH HUB
1. Using SST, remove the high speed output gear bushing and clutch hub.
  1. SST 09950-00020, 09950-00030, 09950-60010 (09951-00320)
  Fig 7: Removing High Speed Output Gear Bushing & Clutch Hub Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a magnetic finger, remove the straight pin from the differential front case.
REMOVE REAR TAPER ROLLER BEARING
Using SST and a press, remove the rear taper roller bearing.
1. SST 09950-00020, 09950-60010 (09951-00320)
NOTE: Set the claw of SST to the bearing inner race securely.

Fig 8: Removing Rear Taper Roller Bearing Using SST & Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL REAR CASE
Remove the 12 bolts and differential rear case.

Fig 9: Removing Differential Rear Case & Bolts
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REMOVE THRUST WASHER AND REAR SIDE GEAR

Fig 10: Removing Thrust Washer & Rear Side Gear
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REMOVE PINION SHAFT, 2 PINION GEARS AND 2 THRUST WASHERS
1. Remove the straight pin from the pinion shaft.
  
  Fig 11: Removing Straight Pin From Pinion Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the pinion shaft, 2 pinion gears and thrust washers.
  
  Fig 12: Removing Pinion Shaft, Pinion Gears & Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the front side gear and thrust washer.
  
  Fig 13: Removing Front Side Gear & Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOW GEAR
Using a plastic hammer, tap and remove the low gear.

NOTE: Be careful not to damage the low gear.

Fig 14: Tapping & Removing Low Gear Using Plastic Hammer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002